Pocket article and method of making the same

ABSTRACT

A one piece pocket constructed from a blank of a woven fabric essentially consisting of spaced yarns defining open areas therebetween, the blank being in the shape of a pocket pattern. The blank is folded and seamed at least along a length of adjacent overlapping free edges of the blank to define a pocket with a folded periphery and a seamed free edge periphery. The yarns of a portion of the pocket are essentially fully impregnated with a fiber locking, abrasion resistant substance to render that portion of the pocket resistant to abrasion. The blanks are cut in a conventional manner, such as simultaneously from a plurality of layers of woven material in a stack, utilizing a pattern and minimizing waste material. Impregnation of the fabric fibers may be accomplished by passing the fabric through a roller assembly in communication with treating fluid. Spraying or dipping for purposes of impregnation may also be utilized.

United States Patent 1191 Hall v [54] POCKET ARTICLE AND METHOD OF MAKING THE SAME [76] Inventor: Richard Hall, Rt. No 3, Old Natches Trace Road, Franklin, Tenn. 37064 22 Filed: Aug. 7, 1970 211 Appl.No.: 62,096

1451 Apr. 10, 1973 330,214 3/1960 Great Britain ..2/247 Primary Examiner-Alfred R. Guest AttorneyBums, Doane, Benedict, Swecker and Mathis [57] ABSTRACT A one piece pocket constructed from a blank of a woven fabric essentially consisting of spaced yarns defining open areas therebetween, the blank being in the shape of a pocket pattern. The blank is folded and seamed at least along a length of adjacent overlapping free edges of the blank to define a pocket with a folded periphery and a seamed free edge periphery. The yarns of a portion of the pocket are essentially fully impregnated with a fiber locking, abrasion resistant substance to render that portion of the pocket resistant to abrasion. The blanks are cut in a conventional manner, such as simultaneously from a plurality of layers of woven material in a stack, utilizing a pattern and minimizing waste material. impregnation of the fabric fibers may be accomplished by passing the fabric through a roller assembly in communication with treating fluid. Spraying or dipping for purposes of impregnation may also be utilized.

1 Claim, 6 Drawing Figures PATHHEUAPR 1 01913 INVENTOR RICHARD H. HALL ATTORNEYS POCKET ARTICLE AND METHOD OF MAKING THE SAME BACKGROUND OF THE INVENTION This invention relates to pockets. More particularly this invention relates to a method and article for combating the problem of abrasive wear of pockets.

It is commonly known that abrasive wear of pockets caused by the carrying of coins, keys, etc., as well as by rings or watches rubbing the pocket fabric during removal or deposit of articles therein, is the cause of failure of many pockets.

One prior approach to this problem has been to heat seal or sew an additional thickness of material to the lower portion of the pocket. Apart from the undesirable expenses attributable to the need for extra material and labor involved in such an operation, these pockets may be sometimes undesirable insofar as the outline of the additional thickness of material may be visually detectable. The existence of the additional thickness of material is particularly noticeable in instances where laundered, starched and pressed trousers are involved.

Another approach to the wear problem has been the use of a specially constructed material in which additional warp yarns are provided in selected portions of a woven fabric so as to increase the abrasion resistance of the fabric in the area of those selected portions. A similar approach has involved the incorporation of glass or plastic beads over selected portions of the fabric. Such glass or plastic beads are provided to enhance the abrasion resistance of the fabric.

Both of these latter approaches to solutions of the problem may not be entirely desirable from two standpoints. Initially, they require the additional expense associated with a special order. Moreover, restrictions are inherently placed on pattern markers as to the orientation of the pockets on the fabric material from which they are to be cut, by reason of the need to correctly position portions of the pattern on the abrasion resistant sections of the fabric. Thus, maximum efficient use of the material purchased is prevented, thereby increasing waste.

Many of the above-noted approaches to the abrasion problem connected with pockets are discussed in a U.S. Potter Pat. No. 2,295,425, issued Sept. 8, 1942, in which still another approach to the wear problem is proposed in an attempt to minimize that problem while obviating certain disadvantages of the above-noted approaches. The proposal involves the application of a layer of a rubber coating to the inner pocket surface. The rubber coating is intended to provide resistance to abrasion so as to increase the useful life of the pocket.

The coating approach to the wear problem also suffers from several disadvantages. For example, since a coating is involved, an additional thickness of material is provided at the pocket; and this additional thickness may be visually detectable where trouser pockets are involved.

However, the principal disadvantage of the utilization of a rubber coating is that the coating by its nature inhibits ventilation and evaporation of body moisture from parts of the body in the area of the pocket covered by the coating. It is for this reason that the coating proposed in the Potter patent is applied to a restricted area whichextends a distance approximating only one fourth of the width of the pocket from the seam on each side. Thus, the area of abrasion resistance cannot be made coextensive with the fabric area subject to abrasion.

OBJECTS AND SUMMARY OF THE INVENTION It is, therefore, an object of the present invention to provide a novel pocket article and method of manufacturing the same intended to obviate or minimize the disadvantages previously noted.

A principal object of the invention is to provide such an article and method wherein abrasion resistance over an unrestricted area of the pocket fabric is available without inhibiting the ability of the pocket to breathe, i.e., permit ventilation. and evaporation of moisture.

A further object of the present invention is to provide a novel pocket and method of manufacturing the same wherein the pocket is wear resistant over the lower, closed portion thereof without necessitating the use of a special fabric or multiple layers of a fabric in order to provide wear resistance.

It is still another object of the present invention to provide a novel pocket article and method of manufacturing the same wherein abrasion resistance, adequate ventilation characteristics, and minimization of fabric waste products are all present.

A preferred form of the invention intended to accomplish at least some of the foregoing objects comprises a one piece, single stitched pocket article manufactured from a woven fabric blank. The blank is cut from conventional fabric in the conventional manner, maximizing the utilization of the available fabric in the pocket product. After the fabric blank is cut, it is folded to define a folded periphery, and it is single stitched along adjacent overlapping free edges to define a seamed free edge periphery. A continuous and appreciable portion of the fabric, which on the blank extends the width of the blank between generally opposite edges of the blank, essentially consists of treated spaced yarns defining open areas therebetween. This portion of the fabric preferably includes the entire lower closed end of the pocket and should generally constitute at least one quarter of the fabric area.

The treated portion generally represents that portion of the pocket below the pocket portions attached to a garment. Treatment is accomplished by essentially fully impregnating the fabric yarns with a fiber locking and abrasive resistant substance which renders the impregnated portion wear resistant.

Impregnation of the treated portion of the fabric may be accomplished by passing the fabric through a roller assembly in communication with. treating fluid. Alternatively, spraying of the fluid or dipping of the fabric into the fluid may be utilized to accomplish impregnation. Subsequently, the fabric is dried by standard techniques at some temperature above ambient temperature.

Other objects and advantages of the present invention will become apparent from the following detailed description with reference to the accompanying drawings in which:

THE DRAWINGS FIG. 1 represents a pattern layout on the top layer of a stack of fabric sheets;

FIG. 2 represents a cut but unfolded and unstitched pocket blank to be formed into a pocket article for front or side trouser pockets;

FIG. 3 is a side elevational schematic view of equipment which may be utilized in a portion of the manufacturing process to form an article according to the present invention;

FIG. 4 is a top plan view of the structure shown in FIG. 3;

FIG. 5 is a plan view of the blank shown in FIG. 2 after folding and stitching to form a pocket article; and,

FIG. 6 is a plan view of a folded and stitched hip pocket article according to the present invention.

DETAILED DESCRIPTION With reference to the accompanying drawings, a'

pocket article and method of manufacturing that article each according to the present invention will be discussed.

In FIG. 1, it will be apparent that the initial step in the manufacturing process is the provision of a stack 10 of sheets 12 of woven fabric essentially consisting of spaced yarns defining open areas therebetween. In general, these sheets of fabric will be of the conventional type and do not require specially constructed selected portions, although the present invention may also be advantageous in instances where such fabrics are employed.

In phantom lines in FIG. 1, a pattern layout of pocket blanks is shown at 14. As illustrated, where conventional fabrics are employed, the pattern marker may minimize waste material by orienting the patterns in a manner which makes most efficient utilization of the material available to be cut.

Conventional cutting operations may be employed to simultaneously cut blanks from the plurality of layers by cutting through the stack. For example, an electric fabric knife may be utilized to cut pocket blanks from the stack 10 which may include about 200 layers and be about five inches deep. A plurality of blanks 16, one of which may be seen in FIG. 2, are then provided.

The particular blank shown is generally symmetrical about the fold line extending the length of the blank, as indicated at 18. One portion of the blank conventionally is cut back as shown at to provide an area exposed for attaching the pocket to a garment in a known manner. This area is indicated in FIG. 5 at 22. At 24 is illustrated notches which exemplify a further expedient for facilitating the sewing of the pocket into a garment.

In one process according to the present invention, the blank is treated prior to folding and stitching. Treatment of the blank is for the purpose of impregnating the yarns and fibers of at least a portion of the woven material with a fiber locking substance which is abrasion resistant to render the treated portion of the material wear resistant. One form of so treating the blank is schematically shown in FIGS. 3 and 4. The blanks may be placed with a portion supported on a feeding conveyor means 26 which includes an endless belt 27 rotatable about spaced rollers 28 and 30, one of which is driven by suitable means (not shown).

As shown in FIG. 4, adjacent the conveyor means 26 is a further conveyor means 32 including a power driven belt 34. The upper surface of the belt 34 and the upper surface of the belt27 are at the same level so that the blank may be placed on both belts 27 and 34 simultaneously with the lower half resting on belt 27 as indicated at 36 in FIG. 4.

It will be appreciated that the speeds of the belts 27 and 34 may be controlled in any suitable manner so as to be identical. For example, roller 28 may provide the driven roller for both belts 27 and 34.

The roller 30 may then provide an idle and direction reversing roller for the belt 27. A similar idle and direction reversing roller is provided for the belt 34 at the end thereof remote from the driven roller 28.

Adjacent the belt 34 and longitudinally spaced from and aligned with the conveyor means 26 is a third conveyor means 36 with a belt 37 driven by a power roller 38 at one end, and provided with an idle and reversing roller 40 at the opposite end. This roller 40 may be sufficiently elongated to provide the idle and reversing roller for the belt 34.

In the gap between the conveyor means 26 and 36 a receptacle 41 for treating fluid 42 is mounted on a suitable standard 43. Within the receptacle 41 are a plurality of rollers 44 journaled for rotation on the receptacle walls and partially immersed in the fluid 42. A portion of each of the rollers 44 extends above the top of the receptacle. Suitably mounted above the rollers 44 are feed rollers 46 which are power driven (by means not shown) so as to draw the pocket blank over the immersed rollers 44 during which the blank is treated by engagement with the partially fluid im-- mersed rollers. It will be apparent that the positioning of the feed rollers 46 and the immersed rollers 44 is such that during feeding of the blank by the feed roller 46, the immersed rollers are frictionally caused to rotate in the fluid 42. It will also be apparent that the speed of the feed rollers 46 may be controlled so as to move the blank at the rate of blank movement caused by the conveyor means 34.

The blank is then'feed to the third conveyor means 36 above which a heat generation assembly 48 may be suitably mounted so as to dry the treated fabric. Speed of the belt 37 of this conveyor means 36 may be controlled to correspond to the speed of the belt 34. Subsequently, the blanks are removed and folded and sewn to form the finished pocket article shown in FIG. 5.

Formation of this article involves the folding of the pocket along the fold line to provide a folded pocket periphery 50 and the stitching of the fabric along the overlying or overlapping portions of the free edges thereof to form a seamed free edge periphery 52. Although any number of rows of stitching may be utilized it will be appreciated that a single row of stitching is entirely acceptable by reason of the treatment of the material.

It is readily apparent that the treatment of the woven material may be accomplished through operations other than the one described above. For example, either the blank or the folded and stitched article may be dipped by a desired amount into a treating solution. Alternatively, the treating solution may be sprayed over the desired portion of the fabric in any suitable manner.

As previously mentioned, the treating fluid is abrasive resistant and may be of the type commercially available under the trademark PARA SEAL from Western Textile Products, 3400 Tree Court Boulevard, St. Louis, Missouri, or the trademark EDGE-LOX available from Precision Papers, lnc., Chemical Products Division, 84 Ferris Street, Brookland, New York, or under the trademark NO-PRAY available from Sprayway Inc., Chicago, Illinois. These commercially available fluids have been utilized for their sealing characteristics to prevent unraveling of material at seamed edges and generally comprises a neoprene latex or a self curing, cross-linking acrylic emulsion. The purpose of such utilization is to eliminate surging operations in garment manufacture.

Before the fabric is treated according to the present invention, it essentially consists of spaced yarns defining open areas therebetween. These open areas permit the pocket to breathe. After treating and drying, the treated area still essentially consists of spaced yarns defining open areas therebetween. The abrasive resistant characteristics of the treating fluid, however, renders the treated portion resistant to wear while not inhibiting ventilation and evaporation of body moisture. Upon drying, the fluid also locks the overlying yarns and the fibers of the yarns together. Thus, the frictional engagement of the adjacent impregnated yarns is minimized so as to reduce the possibility of wear failure.

As earlier noted, since the fabric is impregnated and not coated, the area of treatment for abrasion resistant characteristics is not restricted. Generally, however, this area will consist of the lower, closed portion of the pocket, i.e. the entire fabric portion below the line 53 shown in FIG. 5. This portion is coextensive with the width of the pocket and includes the fabric on both overlapping sides which define, together with the seamed free edge periphery 52 and the folded periphery 50, the closed pocket portion. In other words, the treated portion is generally that portion of the pocket below the pocket portions to be attached to the garment. The upper area, as indicated at 54in FIG. 5, need not be treated insofar as it is not generally subject to a great amount of abrasion. However, treatment of that portion of the fabric is within the scope of the invention.

On the blank the continuous and appreciable portion of the fabric treated may be viewed as being coextensive with the width of the blank, i.e., extending between opposite sides of the blank, and as extending appreciably along the length of the blank. In FIG. 2 the 56 and the seamed free edge periphery is shown at 58. 1

The treated fabric in the finished pocket preferably extends below the line illustrated at 60. As will be apparent, if a hip pocket blank is treated prior to the folding and stitching, the treated portion will be generally in the middle of the blank since the blank is to be folded, along its width.

It will be appreciated that although the invention has been described in connection with preferred articles.

and methods, additions, substitutions, modifications and deletions may be made without departing from the spirit or scope of the invention as defined-in the appended claims. For example, a bolt of cloth might be selectively treated by the manufacturer thereof in accordance with the invention to provide resistant areas from which blanks could be cut in the fashion of the special order reinforced material earlier described.

What is claimed is:

1. A pocket comprising a blank of woven fabric essentially consisting of spaced yarns definingopen areas therebetween, said blank being folded to define a folded pocket periphery and seamed at least along a length of the overlapping free edges extending from said folded pocket periphery to define a seamed free edge pocket periphery, said yarns in a continuous and appreciable portion of the pocket, constituting substantially the entire closed end of the pocket, being fully impregnated with a fiber-locking and abrasion resistant substance to render said portion resistant to wear in a manner maintaining said open areas permeable to air flow, said portion being coextensive with the width of the pocket adjacent its lower closed end. 

1. A pocket comprising a blank of woven fabric essentially consisting of spaced yarns defining open areas therebetween, said blank being folded to define a folded pocket periphery and seamed at least along a length of the overlapping free edges extending from said folded pocket periphery to define a seamed free edge pocket periphery, said yarns in a continuous and appreciable portion of the pocket, constituting substantially the entire closed end of the pocket, being fully impregnated with a fiberlocking and abrasion resistant substance to render said portion resistant to wear in a manner maintaining said open areas permeable to air flow, said portion being coextensive with the width of the pocket adjacent its lower closed end. 